Magnetic Field Disruption For In-Well Power Conversion

ABSTRACT

The system invention is based on the use of electromagnetics that convert flow and mechanical motion into electrical power. The system is housed in a side pocket mandrel. Flow is diverted from the main bore through the side pocket, which houses a pressure vessel. At least one magnet is housed in the pressure vessel, and at least one coil is wound around the pressure vessel. As the diverted flow from the well passes through the side pocket, the pressure vessel may rotate or vibrate, creating a disturbance to the magnetic field, thereby creating current. An electronics harvesting module is connected to the ends of the coil which can harvest, regulate, and store power.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No.61/010,812, filed on Jun. 11. 2014.

BACKGROUND OF THE INVENTION

The deployment of gauges and flow control systems in wellbores requirethe use of electrical cables and/or hydraulic lines to provide the powerin the wellbore necessary for the proper operation of these devices. Thecables and tubes are normally placed on the outside of the pipe andstrapped to the tubing.

The deployment of cables and tubing requires a significant amount oftime and effort with additional equipment required on the rig. The riskinvolved for accidents and delays in the deployment of the productiontubing is significant. Also, the cables and tubing may create asignificant challenge when the production pipe is removed from the well.The crushing of the tubing or cut of the tubing may cause the productionpipe to be stuck in the well and a fishing job required to remove thebroken tubing.

The use of packers in the wells creates another challenge to thedeployment of cables. The packers normally do not allow for tubing andcables to pass through the packer. A special and more expensive packeris normally used if the operator wants to run gauges below the packer.

The use of Intelligent Completions in subsea wells has also created asignificant challenge to wellhead manufacturers for connections ofmultiple hydraulic power lines and electric lines. Maintaining theintegrity of multiple lines during the deployment of gauges and flowcontrol systems in wells is also very challenging for the operators.

Finally, the ability to deploy sensors closer to the sandface forproduction surveillance and reservoir performance monitoring as well asfluid characterization is important for production optimization. Theneed for the development of wet connectors to interface the cable at theupper completion to the lower completion cable for power andcommunications will be required for proper deployment of sensors andIntelligent Systems.

The use of wireless communications and elimination of cables isdesirable in the oilfields to improve reliability, decrease costs andimproved the time it takes to deploy the production tubing in the well.Multiple wireless communications systems have been developed foroilfield applications. The systems have to be used in serviceapplications instead of permanent applications due to the short life ofthe batteries used to operate the communications module.

The deployment of wireless systems for communications in the wellboremay be a game changer since the elimination of cables and connectors mayincrease the reliability of completion system and provide for productionoptimization. The elimination of cables and connectors will alsodecrease significantly the time required to deploy pipe in the wellreducing the installation cost significantly and also reducing theequipment required on the rig flow and reducing the number of personsrequired to install the entire system in the well.

The development of power generators that can be used inside wellbores toprovide the necessary long term energy for the operation of downholesystems is critical for the operation of the next generation ofIntelligent Wells.

The generator would collect wellbore energy such as flow and vibrationconverting it into useful electrical power through the use of magnetics.

SUMMARY

The concept for the system is based on the use of magnetics that convertflow and mechanical motion into electrical power.

In an exemplary embodiment, the system comprises a mandrel with a mainbore and a side pocket where a portion of the well's fluid is divertedfrom the main bore through the side pocket. In such exemplaryembodiment, the system further comprises a pressure vessel disposedwithin the side pocket. The pressure vessel rotates or vibrates from theflow diverted through the side pocket. In such exemplary embodiment, thesystem further comprises an electronics harvesting module connected tothe ends of the coils that harvests, regulates, and stores power fromthe coil. At least one magnet is disposed within the pressure vessel,and at least one coil is wound around the pressure vessel.

In an embodiment of the system, the electronics harvesting module storespower with rechargeable batteries, capacitors, or any other retainer ofelectricity.

In another embodiment of the system, the system comprises at least onepiezoelectric wafer or at least one flexible piezo instead of at leastone magnet.

In a preferred embodiment, the system can convert motion into electricpower based on the movement along the long axis of the coil/magnets bythe small magnets. The magnets will vibrate in their sealed pressurevessel based on a stream of flow diverted from the well into the sidepocket of the mandrel.

While preferred aspects and embodiments of the system are shown anddescribed herein, it will be understood that the invention may beembodied otherwise than herein specifically illustrated or described,and that certain changes in form and arrangement of parts and thespecific manner of practicing the system may be made within theunderlying idea or principles of the system.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects, and advantages of the system willbecome better understood with regard to the follow description, appendedclaims, and accompanying drawings where:

The various drawings supplied herein are representative of one or moreembodiments of the present invention.

FIG. 1 shows a cutaway of an exemplary embodiment of the present system.

DESCRIPTION OF EMBODIMENTS

In the Summary above and in the Description of Embodiments, and theclaims below, and in the accompanying drawings, reference is made toparticular features of the system. It is to be understood that thedisclosure of the system in this specification includes all possiblecombinations of such particular features. For example, where aparticular feature is disclosed in the context of a particular aspect orembodiment of the system, or a particular claim, that feature can alsobe used, to the extent possible, in combination with and/or in thecontext of other particular aspects and embodiments of the system, andin the system generally.

Referring now to FIG. 1, an exemplary embodiment of mandrel 1 of thesystem is shown. The mandrel 1 is comprised of a maw bore 2 and a sidepocket 3, also known as a “side pocket mandrel” in the oil & gasindustry.

Referring additionally to FIG. 1, an exemplary embodiment of a pressurevessel 4 is shown disposed within the side pocket 3. Lines of flowthrough the mandrel 1 is shown m FIG. 1 and diverted through the sidepocket 3. Flow through the side pocket 3 facilitates the rotation orvibration of the pressure vessel 4.

Further referring to FIG. 1, in an exemplary embodiment, at least onemagnet 5 is disposed within the pressure vessel 4. Moreover, at leastone coil 6 is wound around the pressure vessel 4. In certainembodiments, a piezoelectric wafer or a flexible piezo can be used inthe place of a magnet 5 to facilitate downhole power generation.

In a preferred embodiment, the system will be developed to convertmechanical and flow energy in the wellbore to electrical power tooperate sensors and flow control modules in the well. The system m suchembodiments will utilize vibrational energy generated by the wellboreflow to generate electrical energy using electromagnetics technology.

Still referring to FIG. 1, in an exemplary embodiment, a magnetic fieldwill be created and exerted onto the coil 6 from at least one magnet 5disposed within the coil 6 wound pressure vessel 4. Any disturbance tothe balanced magnetic field of the pressure vessel 4 will induce acurrent onto the coil 6. In a preferred embodiment, multiple smallpermanent magnets will be mounted adjacent to a fixed pressure vessel 4to vibrate based on the amount of flow passing near the small magnets.

Further referring to FIG. 1, in an exemplary embodiment, an electronicsharvesting module 7 is connected to the ends of the coil 6 thatharvests, regulates, and stores power from the coil 6. In a preferredembodiment, the electronics harvesting module 7 will rectify the ACsignal into a DC signal for storage in an energy storage medium such assuper capacitors, batteries, or any other retainer or storage medium ofelectricity.

In an exemplary embodiment, energy stored in the energy storage medium,such as super capacitors or batteries, can he used, for example, topower dog sensors, operate a flow control module, or powercommunications circuits. The system can be used for main power withbatteries, or any other energy storage medium, being used as a backuppower d there is no flow in the well for extended period of time.

1. A system for generating in situ power inside as well comprising; a. amandrel with a main bore and a side pocket wherein a portion of a well'sfluid flows through the side pocket; b. a pressure vessel disposedwithin the side pocket wherein a module within the pressure vesselrotates or vibrates from the flow diverted through the side pocket; c.at least one magnet disposed within the pressure vessel; d. at least onecoil wound around the pressure vessel; and e. an electronics harvestingmodule connected to the ends of the coil that harvests, regulates, andstores power from the coil.
 2. The system of claim 1 wherein theelectronics harvesting module stores power with rechargeable batteries.3. The system of claim 1 wherein the electronics harvesting modulestores power with capacitors.
 4. The system of claim 1 wherein theelectronics harvesting module stores power with a retainer ofelectricity.
 5. A system for generating in situ power inside a wellcomprising: a. a mandrel with a main bore and a side pocket wherein aportion of a well's fluid flows through the side pocket; b. as pressurevessel disposed within the side pocket wherein as module within thepressure vessel rotates or vibrates from the flow diverted through theside pocket; c. at least one piezoelectric wafer disposed within thepressure vessel; d. at least one coil wound around the pressure vessel;and e. an electronics harvesting module connected to the ends of thecoil that harvests, regulates, and stores power from the coil.
 6. Asystem for generating in situ power inside a well comprising: a. amandrel with a main bore and a side pocket wherein a portion of a well'sfluid flows through the side pocket; b. a pressure vessel disposedwithin the side pocket wherein a module within the pressure vesselrotates or vibrates from the flow diverted through the side pocket; c.at least one flexible piezo disposed within the pressure vessel d. atleast one coil wound around the pressure vessel; and e. an electronicsharvesting module connected to the ends of the coil that harvests,regulates, and stores power from the coil.